Epoxy resin composition for fiber-reinforced composite material, prepreg, and fiber-reinforced composite material

Patent metadata

Field	Value
Publication number	US-9834670-B2
Application number	US-201113823905-A
Country	US
Kind code	B2
Filing date	Sep 22, 2011
Priority date	Sep 24, 2010
Publication date	Dec 5, 2017
Grant date	Dec 5, 2017

Abstract

Provided are a fiber-reinforced composite material excellent in heat resistance and strength properties, an epoxy resin composition to obtain the fiber-reinforced composite material, and a prepreg obtained by using the epoxy resin composition. Further provided are a fiber-reinforced composite material having less volatile matters during the curing time, and having excellent heat resistance and strength properties, an epoxy resin composition to obtain the fiber-reinforced composite material, and a prepreg obtained by using the epoxy resin composition. Provided are: an epoxy resin composition for a fiber-reinforced composite material, comprising an amine type epoxy resin [A], an aromatic amine curing agent [B], and a block copolymer [C] having a reactive group capable of reacting with an epoxy resin; a prepreg obtained by impregnating a reinforced fiber with the epoxy resin composition; and a fiber-reinforced composite material obtained by curing the prepreg. Further provided are: an epoxy resin composition comprising an epoxy resin [A] having two or more of four- or more-membered ring structures, and having either one of a glycidyl amino group directly bonded to the ring structure or a glycidyl ether group directly bonded to the ring structure, epoxy resin [B] having three or more of functional groups, a curing agent [C], and an elastomer component [D]; a prepreg obtained by impregnating a reinforced fiber with the epoxy resin composition; and a fiber-reinforced composite material obtained by curing the prepreg.

First claim

The invention claimed is:

1. An epoxy resin composition for fiber-reinforced composite materials comprising:
[A] a glycidyl amino groups-containing epoxy resin component which comprises a polyfunctional glycidyl amino groups-containing epoxy resin and a difunctional glycidyl amino groups-containing epoxy resin;
[B] an aromatic amine curing agent;
[C] a block copolymer having a reactive group capable of reacting with a glycidyl group-containing resin, wherein the reactive group is selected from a carboxyl group and an oxirane group; and
one or more optional epoxy resins, other than [A];
wherein [A] accounts for 80 to 100 parts by weight of 100 parts by weight of total epoxy resin content; and
wherein [C] is present in an amount of 2 to 15 parts by weight per 100 parts by weight of total epoxy resin content.

2. The epoxy resin composition for fiber-reinforced composite materials as described in claim 1 , wherein the reactive group capable of reacting with a glycidyl group-containing resin that is contained in block copolymer [C] is a carboxyl group.

3. The epoxy resin composition for fiber-reinforced composite materials as described in claim 2 , wherein block copolymer [C] having a reactive group capable of reacting with an epoxy resin is at least one block copolymer chosen from the group consisting of S-B-M, B-M and M-B-M, each of the blocks being connected to another by means of a covalent bond or an intermediate molecule connected to one of the blocks via a covalent bond and to the other block via another covalent bond, block M comprising a copolymer containing at least 50 mass % of a homopolymer of polymethyl methacrylate or methyl methacrylate and also comprising a reactive monomer as a copolymerization component, block B being incompatible with block M and having a glass transition temperature of 20° C. or less, and block S being incompatible with blocks B and M and having a glass transition temperature higher than that of block B.

4. The epoxy resin composition for fiber-reinforced composite materials as described in claim 1 , wherein the polyfunctional glycidyl amino groups-containing epoxy resin accounts for 30 to 70 parts by weight of 100 parts by weight of total epoxy resin content; and the difunctional glycidyl amino groups-containing epoxy resin accounts for 20 to 50 parts by weight of 100 parts by weight of total epoxy resin content; provided that said polyfunctional and difunctional glycidyl amino groups-containing epoxy resins together account for 80 to 100 parts by weight of 100 parts by weight of total epoxy resin content.

5. The epoxy resin composition for fiber-reinforced composite materials as described in claim 1 wherein aromatic amine curing agent [B] is diaminodiphenyl sulfone or a derivative or isomer thereof.

6. The epoxy resin composition for fiber-reinforced composite materials as described in claim 1 having a complex viscosity at 80° C. in the range of 0.1 to 200 Pa*s.

7. A hardened epoxy resin material for fiber-reinforced composite materials obtained by curing the epoxy resin composition for fiber-reinforced composite materials as described in claim 1 and having phase separation structures with a size in the range of 0.01 to 5 μm.

8. A fiber-reinforced composite material comprising the hardened epoxy resin material as described in claim 7 and reinforcement fiber.

9. A prepreg obtained by impregnating reinforcement fiber with the epoxy resin composition for fiber-reinforced composite materials as described in claim 1 .

10. A prepreg as described in claim 9 wherein the reinforcement fiber is carbon fiber.

11. A fiber-reinforced composite material obtained by curing the prepreg as described in claim 9 .

12. A fiber-reinforced composite material as described in claim 11 wherein the reinforcement fiber is carbon fiber.

Assignees

• Mizuki Maki
• Goto Yuko
• Tomioka Nobuyuki
• Sakata Hiroaki
• Taiko Hiroshi
• Toray Industries

Inventors

• Mizuki Maki
• Goto Yuko
• Tomioka Nobuyuki
• Sakata Hiroaki
• Taiko Hiroshi

Classifications

• C08G59/4246

  polymers with carboxylic terminal groups · CPC title

• C08L63/00 Primary

  Compositions of epoxy resins; Compositions of derivatives of epoxy resins · CPC title

• C08G59/5033

  aromatic · CPC title

• C08G59/504

  containing an atom other than nitrogen belonging to the amine group, carbon and hydrogen · CPC title

• C08G2261/126

  block · CPC title